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Home >> Dodge >> 1996 >> Stealth R/T V6-2972cc 3.0L DOHC >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Service and Repair >> Disassembly and Assembly >> Part 1 of 2

Part 1 of 2












TRANSAXLE DISASSEMBLY AND REASSEMBLY

DISASSEMBLY SERVICE POINTS

A - SPRING PIN REMOVAL




Remove the spring pin.

NOTE: If the spring pin interferes with the synchronizer ring or cone gear, rotate the gear for dislocation and remove the Spring pin.

B - LOCK NUTS REMOVAL




1. Unstake lock nuts of the input shaft and intermediate gear.




2. Shift the transaxle in reverse using the control lever and select lever.




3. Install the special tool onto the input shaft.
4. Screw a bolt 10 mm (0.39 in.) into the hole on the periphery, of clutch housing and attach a spinner handle to the special tool.
5. Remove the lock nut, while using the bolt as a spinner; handle stopper.

C - SPRING PINS REMOVAL




Remove the spring pins for 1st-2nd and 3rd-4th speed shift forks.

D - SHIFT RAIL ASSEMBLY REMOVAL




1. Shift the 1st-2nd speed shift fork to the 2nd speed.
2. Shift the 3rd-4th speed shift fork to the 4th speed.




3. Remove the shift rail assembly.

INSPECTION

BACKUP LIGHT SWITCH




Operate the backup light switch to check continuity with a circuit tester. If no continuity, replace the switch.

REASSEMBLY SERVICE POINTS

A - OIL SEAL INSTALLATION








Install the drive shaft oil seal using the special tool.

B - OIL SEAL INSTALLATION








Install the input shaft front oil seal using the special too

C - ADHESIVE APPLICATION TO BOLT




Apply MOPAR part No.4318031 or No.4318032 or equivalent adhesive to the bolt threads.

CAUTION: Do not apply to the bolt head.

D - SHIFT RAIL ASSEMBLY INSTALLATION




1. Set the 1st-2nd speed shift sleeve at 2nd speed.
2. Set the 3rd-4th speed shift sleeve at 4th speed.
3. Fit the shift forks of shift rail assembly to groove of sleeves.




4. Insert the shift rails into the shift rail holes of clutch housing.
5. Turn the shift rails in the directions indicated by the arrows in the order shown in the illustration, and engage the shift lugs to control finger and the interlock plate.

E - SPRING PINS INSTALLATION




1. Install the spring pins using the special tool or a pin punch.

CAUTION: Do not reuse the spring pins.




2. When installing, make sure that the slit of the spring pin is aligned with the shift rail center line.

F - REVERSE IDLER GEAR SHAFT INSTALLATION




Install in the direction illustrated.

G - SPACERS INSTALLATION




1. Place two pieces of solder measuring about 10 mm (0.39 in.) in length and 1.6 mm (0.063 in.) in diameter as illustrated and install the outer races.
2. Install the transaxle case and tighten the bolts to specified torque.
3. Remove the transaxle case.
4. Remove the outer races and remove the solder.
5. If solder is not crushed, perform steps 1 through 4 with a solder with a larger diameter.




6. Measure the thickness of the crushed solder with a micrometer and select and install a spacer of thickness that gives standard preload and end play.
Standard value:
Input shaft end play 0-0.05 mm (0-0.0020 in.)
Intermediate gear preload 0.05-0.10 mm (0.0020-0.0039 in.)
Output shaft preload 0.05-0.10 mm (0.0020-0.0039 in.)
Differential case preload 0.05-0.10 mm (0.0020-0.0039 in.)

H - OIL SEAL INSTALLATION




Install the drive shaft oil seal using the special tool.

I - OIL GUIDE INSTALLATION




Install the oil guide to the transaxle case as illustrated.

J - TRANSAXLE CASE INSTALLATION




1. Place the selected spacers on the intermediate gear and differential's bearing outer race. Also insert the selected, spacer between the output shaft bearing outer race and the transaxle case.
2. Set so that the threaded hole of the reverse idler gear shaft's head is facing in the direction indicated in the illustration.

NOTE: If there is a great deviation in the direction in which the threaded hole is facing, it will be impossible to align the threaded hole and the hole in the case after the transaxle case is installed.




3. Apply MITSUBISHI genuine Part No. MD997740 or equivalent sealant to the clutch housing side of the transaxle case.

CAUTION: Squeeze out sealant from the tube uniformly without excess or discontinuity.

4. Install the transaxle case onto the clutch housing.




5. Insert a Phillips screwdriver [8 mm (0.32 in.) shaft diameter] into the bolt hole in the case, as shown in the image, and use it to align the threaded hole of the reverse idler gear shaft with the bolt hole in the transaxle case.
6. Install the reverse idler gear shaft bolt finger tight.
7. Tighten the all transaxle tightening bolts to specified torque.
8. Tighten the reverse idler gear shaft bolt to specified torque.

K - LOCK NUTS INSTALLATION




1. Install the special tool to the splined end of input shaft.
2. Screw a bolt [10 mm (0.39 in.)] into the hole on the periphery of clutch housing and attach a spinner handle to the special tool.




3. Shift the transaxle in reverse using control lever and select lever.
4. Tighten the lock nut to specified torque, while using the bolt attached in the above step as a spinner handle stopper.
5. Loosen the lock nuts.
6. Retighten the lock nuts to the specified torque.
7. Stake the lock nut.

L - SPRING PIN INSTALLATION




1. Install the spring pin using the special tool or a pin punch.

CAUTION: Do not reuse the spring pins.




2. When installing, make sure that the slit of the spring pin is aligned with the shift rail center line.

M - SEALANT APPLICATION TO AIR BREATHER




Apply MOPAR Part No.4318025 or equivalent sealant to air breather mounting portion and install to the clutch housing.

N - SCREW BOLTS INSTALLATION




Apply MOPAR Part No.4318031 or No.4318032 or equivalent adhesive to screw bolts mounting portion.

O - SEALANT APPLICATION TO THE REAR COVER




Apply MITSUBISHI genuine Part No. M0997740 or equivalent sealant to the rear cover.

CAUTION: Squeeze out sealant from the tube uniformly without excess or discontinuity.




5TH SPEED SYNCHRONIZER DISASSEMBLY AND REASSEMBLY

INSPECTION




SYNCHRONIZER SLEEVE AND HUB
- Combine the synchronizer sleeve and hub and check that they slide smoothly.
- Check that the sleeve is free from damage at its inside front and rear ends.
- Check for wear of the hub front end (surface in contact with the 5th speed gear).

CAUTION: When replacing, replace the synchronizer hub and sleeve as a set.




SYNCHRONIZER KEY AND SPRING
- Check for wear of the synchronizer key center protrusion.
- Check the spring for weakness, deformation and breakage.

REASSEMBLY SERVICE POINT

A - SYNCHRONIZER HUB/SYNCHRONIZER KEY/SYNCHRONIZER SPRING INSTALLATION




1. Assemble the synchronizer hub, and key noting their direction.




2. Assemble the synchronizer spring so that its projection may be engaged in the groove of the synchronizer key.

NOTE: Take care to prevent the projections of the front and rear spring from sitting in the groove of the same key.




INPUT SHAFT DISASSEMBLY AND REASSEMBLY

DISASSEMBLY SERVICE POINTS

A - TAPER ROLLER BEARING REMOVAL




Remove the front bearing using the special tool as illustrated.

B - BEARING SLEEVE REMOVAL




Remove the bearing sleeve using the special tool as illustrated.

C - TAPER ROLLER BEARING REMOVAL




Remove the taper roller bearing together using the special tool as illustrated.

D - 3RD SPEED GEAR REMOVAL




Remove the bearing sleeve, 3rd-4th speed synchronizer assembly and 3rd speed gear together using the special tool as illustrated.

INSPECTION




INPUT SHAFT
- Check the outer surface of the input shaft where the needle bearing is mounted for damage, abnormal wear and seizure (portion A).
- Check the splines for damage and wear.

NEEDLE BEARING
- Combine the needle bearing with the shaft or bearing sleeve and gear and check that it rotates smoothly Without abnormal noise or play.
- Check the needle bearing cage for deformation.




SYNCHRONIZER RING
- Check the clutch gear teeth for damage and breakage.
- Check paper lining on cone I.D. for damage, wear, and flaking.




- Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if it is out of specification.
Limit: 0.5 mm (0.020 in.)




SYNCHRONIZER SLEEVE AND HUB
- Combine the synchronizer sleeve and hub and check that they slide smoothly.
- Check that the sleeve is free from damage at its inside front and rear ends.
- Check for wear of the hub end surfaces (in contact with each speed gear).

CAUTION: When replacing, replace the synchronizer hub and sleeve as a set.




SYNCHRONIZER KEY AND SPRING
- Check for wear of the synchronizer key center protrusion
- Check the spring for deterioration, deformation and breakage.




SPEED GEARS
- Check the bevel gear and clutch gear teeth for damage and wear.
- Check the synchronizer cone for rough surface, damage and wear.
- Check the gear bore and front and rear ends for damage and wear.



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